Garage door bracket

ABSTRACT

A bracket assembly attaches a garage door track to the ceiling joists or another structural support. In one embodiment, an upper bracket includes an upper horizontal element, a lower horizontal element, and at least one support element extending between the upper and lower horizontal elements. The upper element may include a ceiling flange that is angled approximately ninety degrees from the remainder of the bracket. A vertical bracket member attaches to the upper horizontal element, the lower horizontal element and the garage door track. The bracket can reduce installation time, labor, and the potential for error from the typical installation arrangement and method by reducing the number of cuts that the installer must make, and by reducing the number of fasteners that are needed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority under 35 U.S.C. 120 ofU.S. Patent Provisional Application 61/047,934, filed Apr. 25, 2008,which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to garage door tracks, and moreparticularly to a bracket for hanging a garage door track and/or garagedoor opener from a support structure, such as a ceiling joist.

Garage doors typically include wheels on each side that travel up anddown tracks formed from C-shaped channels. The tracks include a verticalportion extending along the side of the garage door opening and ahorizontal portion extending into the garage away from the garage dooropening. The vertical portion is attached to the garage door opening,and the horizontal portion is attached to the ceiling by hanging fromthe ceiling joists. A typical arrangement for attaching the horizontalportion 10 to the ceiling joists 12, 14 is shown in FIG. 1. In thisarrangement, a horizontal L-shaped bracket 16 is attached directly tothe ceiling joists 12, 14. More specifically, the bracket 16 includes afirst flange 18 parallel with the ceiling and a second flange 20extending away from the ceiling perpendicular to the first flange 18.The flanges 18, 20 each include a series of fastener holes 22 alongtheir lengths. The first flange 18 is connected to the ceiling joists12, 14 with lag bolts 24 extending through the holes in the first flange18 and into the joists 12, 14. The second flange 20 receives a bolt 26that connects the horizontal bracket 16 to an L-shaped vertical bracket30. Similar to the horizontal bracket 16, the vertical bracket 30includes a first flange 32 with a series of holes 34, and a secondflange 36 with a series of holes 38. The bolt 26 extends through thefirst flange 32 of the vertical bracket 30 and the second flange 20 ofthe horizontal bracket 16. A sway bracket 40 extends on an angle betweenthe second flange 20 of the horizontal bracket 16 and the first flange32 of the vertical bracket 30 to provide support and prevent lateralmovement of the vertical bracket 30. The sway bracket 40 is connected tothe horizontal bracket with a bolt 42 and to the vertical bracket withan additional bolt 44. Finally, the vertical bracket 30 connects to thehorizontal portion 10 of the garage door track with a bolt 46 thatextends through one of the holes 38 in the second flange 36 of thevertical bracket 30 and a hole in the garage door track 10.

Assembly of the above-described garage door track bracket arrangementinvolves a series of steps. The garage door installer must (1) measurethe distance between ceiling joists, (2) cut the horizontal bracket to aproper length, (3) measure the distance between the ceiling and thehorizontal portion of the track, (4) cut the vertical bracket to theproper length, (5) measure and cut the sway bracket to a proper length,(6) attach the horizontal bracket to the ceiling joists with two lagbolts, (7) attach the horizontal, vertical and sway brackets togetherwith three bolts and (8) attach the vertical bracket to the garage doortrack with a bolt. Although this system and method is very widely knownand used, it can be unfavorable, primarily because the installationsteps are time consuming and labor intensive, and because they providemultiple opportunities for error by the installer.

SUMMARY OF THE INVENTION

The embodiments of the present invention provide a garage door trackbracket that attaches between the ceiling joists and the verticalbracket member. The bracket can save time, labor and materials duringinstallation while reducing the opportunities for error.

In one embodiment, the bracket includes an upper horizontal element, alower horizontal element, and at least one support element extendingbetween the upper and lower horizontal elements. The upper element mayinclude a ceiling flange that is angled approximately ninety degreesfrom the remainder of the bracket. The vertical bracket member attachesto the upper horizontal element, the lower horizontal element and thetrack.

In another embodiment, the lower horizontal element is substantiallyshorter than the upper horizontal element and the upper and lowerhorizontal elements are connected by three support elements. A firstsupport element extends between the first ends of the upper and lowerhorizontal elements and is perpendicular to the upper and lowerhorizontal elements. A second support element extends between the secondends of the upper and lower elements, and due to the difference inlengths between the upper and lower elements, the second support elementextends on an angle between the upper and lower support elements. Athird support element is positioned between the first and second supportelements and extends perpendicular to the upper and lower horizontalelements.

Attachment of the garage door track to the ceiling joists with thebracket of the present invention includes the steps of: (1) attachingthe ceiling flange to the ceiling, (2) measuring the distance betweenthe ceiling and the track and cutting the vertical bracket member to theproper length, (3) attaching the vertical bracket member to the upperand lower horizontal members of the bracket with two bolts and (4)attaching the track to the vertical bracket member with a bolt.

The bracket can reduce installation time and labor from the typicalinstallation arrangement and method by reducing the number of cuts thatthe installer must make, and by reducing the number of fasteners thatare needed. The reduction in measuring and cutting may also lower thechances for error by the installers.

These and other objects, advantages, and features of the invention willbe readily understood and appreciated by reference to the detaileddescription of the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a prior art arrangement for connecting agarage door track to the ceiling joists.

FIG. 2 is an exploded perspective view of a bracket, ceiling joists andgarage door track according to one embodiment of the present invention.

FIG. 3 is an assembled perspective view of the FIG. 2 embodiment.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A system and method for attaching a garage door track 100 to one or moreceiling joists 102, 104 according to one embodiment of the presentinvention is shown in FIGS. 2 and 3. In the illustrated embodiment, theattachment system generally includes a bracket 106 and a verticalbracket member 108.

The garage door track 100 is typically a channel having a C-shaped crosssection, such that the wheels of the garage door (not shown) can ridewithin the track. The track 100 includes a vertical portion (not shown)that extends alongside the opening of the garage door frame, and ahorizontal portion that curves rearwardly from the vertical portion andruns approximately parallel to the ceiling. As illustrated, thehorizontal portion of the track 100 includes a plurality of holes 110for receiving one or more fasteners to support the track 100. Althoughnot shown, each garage door typically includes two tracks, one on eachside of the garage door. The ceiling joists 102, 104 are typicallywooden beams that extend horizontally, generally parallel to thehorizontal portion of the track 100. The joists run parallel to eachother and are commonly spaced apart at even intervals. They may extendacross the garage in a front-to-back direction, or in a side-to-sidedirection, or in another direction.

In the illustrated embodiment, the bracket 106 includes an upper member112, a lower member 114, and three support members 116, 118 and 120. Aceiling flange 124 extends outwardly at an angle from the upper member112. In one embodiment, the bracket 106 is formed from a single, unitarypiece of material, such as sheet steel, for instance, by a stampingprocess. Other metals may otherwise be used, or alternatively, thebracket may be formed from plastic or another material capable ofbearing the weight of a garage door. In one embodiment, the upper member112, lower member 114 and support members 116, 118 and 120 lie insubstantially same plane, and the ceiling flange 124 extends outwardlyfrom an upper edge 126 of the upper member 112 generally perpendicularto the plane of the upper member 112. The bracket 106 may be formed, forexample, by stamping the desired shape into the sheet steel and thebending the ceiling flange to the desired angle, or by another knownmanufacturing method.

In the illustrated embodiment, the upper member 112 is generallystraight, having a first end 128, a second end 130 and a longitudinallength extending between the first and second ends. As shown, the uppermember further includes an upper edge 126 and a lower edge 132. Theceiling flange 124 is also generally straight, and includes a first end136, a second end 138 opposite the first end, and a longitudinal lengthextending between the first 136 and second 138 ends. In one embodiment,the longitudinal length of the upper member 112 is about 25½ inches. Thelongitudinal length of the ceiling flange 124 may be the same as that ofthe upper member 112, or it may vary from that of the upper member 112.In the illustrated embodiment, the length of the ceiling flange 124 isthe same as the upper member 112 such that the ceiling flange is capableof spanning the spacing of most ceiling joists. In one embodiment, theceiling flange has a width of about 1¼ inches.

The lower member 114 is spaced from the upper member 112, and generallyincludes an upper edge 140, a lower edge 142, a first end 144, a secondend 146 and a longitudinal length extending between the first and secondends. As shown, the lower member 114 is generally parallel to the uppermember 112, however, it may extend at an angle to the upper member 112.In one embodiment, the longitudinal length of the lower member 114 isshorter than that of the upper member 112, to reduce the amount ofmaterial used for each bracket 106. More specifically, in theillustrated embodiment, the longitudinal length of the lower member isabout 12½ inches.

In one embodiment, the bracket 106 includes at least one support memberextending between the upper 112 and lower 114 members. As illustrated,the bracket 106 includes a first support member 116, a second supportmember 118 and a third support member 120. The first support member 116extends between the first end 128 of the upper member 112 and the firstend 144 of the lower member 114. As shown, the first support member isabout 1½ inches wide, and it has a longitudinal length of about 3inches. The second support member 118 is spaced from the first supportmember 116 and extends approximately parallel to the first supportmember 116. As shown, the second support member 118 is about 1½ incheswide, has a longitudinal length of about 3 inches, and is spaced about 7inches from the first support member 116. The third support member 120extends between the second end 130 of the upper member 112 and thesecond end 146 of the lower member 114. As such, it extends on an anglefrom the first 116 and second 118 support members and the upper 112 andlower 114 members. Although the present invention is shown with threesupport members, the number of support members may vary, depending onthe material used for the bracket and the weight requirements that thebracket is required to support. The support members may be spaced apartat varying distances as desired from application to application.

As shown in FIGS. 2 and 3, the ceiling flange 124, upper member 112 andlower member each include a series of holes 150 extending along theirlongitudinal lengths. In one embodiment, the holes 150 are spaced evenlyapart, although the spacing may vary from application to application. Asshown, a first one of the holes 150 is located proximate to the firstends of each of the ceiling flange 124, the upper member 112 and lowermember 114, and the holes extend along the longitudinal lengths of theceiling flange 124, upper member 112 and lower member 114 for about 12½inches. An additional hole 152 is located in the ceiling flangeproximate to the second end 138. In this embodiment, the bracket 106 canaccommodate a track 100 located anywhere between two joists that arespaced apart at about 25 inches or less, because the bracket 106 byrotating the bracket 180 degrees. Alternatively, the upper member 112,lower member 114 and ceiling flange 124 may each include one or moreholes at any other desired positions along their lengths, includingalong their entire lengths. In another embodiment, one or more holes maybe included in the support members. In yet another embodiment, one ormore of the bracket members may include a strengthening rib formedtherein. For instance, in the illustrated embodiment, a strengtheningrib 154 extends along the lengths of each of the upper member 112, lowermember 114 and the support members 116, 118 and 120.

The vertical bracket member 108 is typically an L-shaped channel havinga first body member 160 and a second body member 162. The body members160 and 162 may be formed from a variety of materials, similar to thebracket 106, and in one embodiment the vertical bracket member 108 isformed from sheet steel. The vertical bracket 108 may include a firstend 164 and a second end 166, and each of the members 160 and 162 mayinclude a series of holes 168 spaced apart along its length. In oneembodiment, the spacing of the holes 168 and the distance between theupper 112 and lower 114 members of the bracket 106 correspond such thatone of the holes 168 can be aligned with a holes 150 on the upper member112 while a second hole 168 aligns with a hole 150 on the lower member114.

In one embodiment, installation of the bracket 106 and attachment of thebracket 106 to a garage door track 100 includes the steps of: (1)attaching the bracket 106 to the ceiling joists 102, 104 by extending afirst lag bolt 170 through one of the holes 150 in the ceiling flange124 and into a first ceiling joist 102 and a second lag bolt 172 throughthe hole 152 in the ceiling flange 124 and into a second ceiling joist104; (2) measuring the distance between the ceiling joists and thegarage door track 100 and cutting a vertical bracket member 108 to aproper length; (3) attaching the first body member 160 of the verticalbracket member 108 to the upper horizontal member 112 by extending abolt 174 through a hole 150 in the upper member 112 and a hole 168 inthe vertical bracket 108 and fastening a nut 176 to the bolt 174; (4)attaching the first body member 160 of the vertical bracket member 108to the lower horizontal member 114 by extending a bolt 178 through ahole 150 in the lower member 114 and a hole 168 in the vertical bracket108 and fastening a nut 180 to the bolt 178; and (5) attaching thesecond body member 162 of the vertical bracket 108 to the garage doortrack 100 by extending a bolt 182 through a hole 168 in the verticalbracket 108 and a hole 110 in the track 100 and fastening a nut 184 tothe bolt 182. Of course, alternative fasteners may be used instead ofthe nuts and bolts. As noted above, when fastening the bracket 106 ofthe illustrated embodiment to the joists 102, 104, the installer mayfirst determine the location of the track 100 between the joists 102,104 (i.e. whether the track is closer to the first joist 102 or to thesecond joist 104) and orient the bracket 106 accordingly beforeattaching it to the joists 102, 104.

The above description is that of various embodiments of the invention.Various alterations and changes can be made without departing from thespirit and broader aspects of the invention. Further, the terms“horizontal” and “vertical” are used in the application to generallydescribed the orientation of the components of the invention withrespect to each other and their surroundings, and are not intended torequire a specific orientation or direction.

1. A bracket assembly adapted to join a garage door track with at leastone joist, comprising: an upper horizontal element adapted to beattached to the at least one joist; a lower horizontal element; at leastone support element attached to the upper and lower horizontal elements;and a vertical bracket member adapted to be attached to the track and atleast one of the upper and lower horizontal elements.
 2. The bracketassembly of claim 1 wherein the upper horizontal element includes afirst flange parallel with and attached to a bottom surface of the joistand a second flange extending outward from the bottom surface of thejoist.
 3. The bracket assembly of claim 2 wherein the vertical bracketis adapted to be attached to the second flange.
 4. The bracket assemblyof claim 3 wherein at least one of the first and second flanges, thelower horizontal element and the vertical bracket member defines aplurality of holes adapted to receive a fastener.
 5. The bracketassembly of claim 4 wherein at least one hole on the upper horizontalelement is aligned with at least one hole on the lower horizontalelement, wherein said vertical bracket is fastened to the upper andlower horizontal elements at said aligned holes.
 6. The bracket assemblyof claim 3 wherein the upper and lower horizontal elements are connectedby first, second and third support elements.
 7. The bracket assembly ofclaim 6 wherein the first support element extends between a first end ofthe upper horizontal element and a first end of the lower horizontalelement, the first support element being generally perpendicular to theupper and lower horizontal elements.
 8. The bracket assembly of claim 7wherein the third support element extends between a second end of theupper horizontal element and a second end of the lower element.
 9. Thebracket assembly of claim 8 wherein the lower horizontal element isshorter than the upper horizontal element, wherein the third supportelement extends on an angle between the upper and lower supportelements.
 10. The bracket assembly of claim 8 wherein the second supportelement is positioned between the first and second support elements. 11.The bracket assembly of claim 10 wherein the second support element isgenerally parallel to the first support member.
 12. A method ofattaching a garage door track to a joist with a bracket, the brackethaving a an upper horizontal element, a lower horizontal element, atleast one support element connecting the upper and lower horizontalelements, and a vertical bracket, the method comprising: attaching theupper horizontal element to the ceiling joist; measuring the distancebetween the ceiling and the track; cutting the vertical bracket memberto a length that generally corresponds to the distance between theceiling and track; attaching the vertical bracket member to the upperand lower horizontal members of the bracket; attaching the track to thevertical bracket member.
 13. The method of claim 12 wherein the upperhorizontal element includes first and second flanges, wherein the methodcomprises arranging the first flange to be generally parallel to abottom surface of the joist.
 14. The method of claim 13 furthercomprising arranging the lower horizontal element to be parallel withthe upper horizontal element.
 15. The method of claim 14 furthercomprising attaching vertical bracket member to the second flange. 16.The method of claim 14 further comprising connecting the upper and lowerhorizontal elements with first, second and third support elements. 17.The method of claim 16 further comprising attaching the first supportelement to a first end of the upper horizontal element and to a firstend of the lower horizontal element.
 18. The method of claim 17 furthercomprising attaching the third support element to a second end of theupper horizontal element and to a second end of the lower horizontalelement, wherein the lower horizontal element is shorter than the upperhorizontal element, wherein the third support element extends betweenthe upper and lower horizontal elements on an angle.
 19. The method ofclaim 18 further comprising positioning the second support elementbetween the first and third horizontal element.
 20. The method of claim19 wherein the upper and lower horizontal elements and the verticalbracket member each define a plurality of holes, wherein the methodcomprises securing the vertical bracket member to the upper and lowerhorizontal members with a fastener.
 21. A bracket assembly forconnecting a garage door track to a ceiling support element, comprising:a one-piece, unitary sheet metal bracket including an elongated uppermember having first and second ends, an elongated lower member havingfirst and second ends, a support member extending between the uppermember and the lower member, and an attachment flange extending from theupper member generally perpendicular to the upper member for attachingthe sheet metal bracket to the ceiling support member, the upperelongated member defining a first fastener hole and the lower elongatedmember defining a second attachment hole, the first and secondattachment holes aligned along a line that is generally perpendicular tothe longitudinal extent of the upper elongated member; and an elongatedvertical support member connected to the sheet metal bracket and thegarage door track, the vertical support member including a firstportion, a second portion, and a third portion, the first portionattached to the upper elongated member of the sheet metal bracket by afirst fastener extending through the first fastener hole, the secondportion attached to the lower elongated member of the sheet metalbracket by a second fastener extending through the second fastener hole,and the third portion capable of attaching to the garage door track by afastener extending through the third portion and the garage door track.